Form No. 3442-428 Rev A TITAN® Max Service Manual Published: XX 2020 © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision History Page 2 TITAN® Max Service Manual 3442-428 Rev A
Preface This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. We are hopeful that you will find this manual a valuable addition to your service shop.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S.
Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
Preface Page 6 TITAN® Max Service Manual 3442-428 Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–3 Equivalents and Conversions............................................................................................................. 2–8 U.S.
Specifications TITAN® Max Specifications Model 76601 Engine 26 HP Kohler with Pro Air Cleaner Engine Model KT745-3094 Engine Displacement 747cc 3600 ± 100 Engine Speed Engine Oil Capacity 1.9 L (64 fl oz) with oil filter Frame/Axle Width Fully Welded Tubular Frame Deck Size 152.4 cm (60 inches) Deck Configuration 3-Blade Deck Construction Fabricated 4 Point HOC Type HOC Range 3.81–12.7 cm (1.5-5.0 inches) Fuel Tank Capacity 26.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply for all fasteners which do not have a specific requirement identified in the service manual.
Metric Bolts and Screws g272209 Figure 2 1. Class 8.8 Specifications and Maintenance: Torque Specifications 2. Page 2–4 Class 10.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) in-lb in-lb N • cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 1/4-20 UNC 48 ± 7 53 ± 7 1/4-28 UNF 53 ± 7 5/16-18 UNC 5/16-24 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolt
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb N • cm in-lb N • cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lb N • m ft-lb N • m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N • m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N • m M12 X 1.25 Class 8.8 80 ± 10 ft-lb 108 ± 14 N •m M12 X 1.5 Class 8.
Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.969 21/32 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Specifications and Maintenance: Torque Specifications Page 2–10 TITAN® Max Service Manual 3442-428 Rev A
Chapter 3 Troubleshooting Table of Contents General Troubleshooting .......................................................................................................................
GEARS The Systematic approach to defining, diagnosing and solving problems.
General Troubleshooting Problem The starter does not crank The engine does not start, starts hard, or fails to keep running Engine loses power TITAN® Max Service Manual 3442-428 Rev A Possible Cause Corrective Action The blade control switch (PTO) is engaged. Move the blade-control switch (PTO) to the disengaged position. The parking brake is not engaged. Set the parking brake. The motion-control levers are not in the Neutral-Lock position.
General Troubleshooting (continued) Problem The engine overheats The mower pulls to the left or right (with levers fully forward) The machine does not drive The machine vibrates abnormally The machine produces an uneven cutting height The blades do not rotate Troubleshooting: General Troubleshooting Possible Cause Corrective Action The engine load is excessive. Reduce the ground speed. The oil level in the crankcase is low. Add oil to the crankcase.
General Troubleshooting (continued) Problem The clutch does not engage TITAN® Max Service Manual 3442-428 Rev A Possible Cause Corrective Action The fuse is blown. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. There is a low voltage supply at the clutch. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary. The coil is damaged. Replace the clutch.
Troubleshooting: General Troubleshooting Page 3–6 TITAN® Max Service Manual 3442-428 Rev A
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Engine Replacement..........................................................................................................................
General Information The Titan Max uses A 26 HP 747cc Kohler twin cylinder OHV 4 cycle engine with a pro air cleaner (KT745-3094).
Service and Repairs Engine Assembly g341898 Figure 3 1. Engine 6. PTO Clutch 2. Oil Drain Hose Assembly 7. Flat Idler Pulley 3. Muffler 8. Idler Arm Assembly 4. Engine Sheave 9. V-belt 5.
Engine Replacement Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Drain the oil into a suitable container. 4. Close the fuel supply. g344221 Figure 4 5. Remove the engine guard. 6. Remove the deck drive belt from the mower deck. Deck Drive Belt Removal (page 6–10) 7.
Engine Removal (continued) g335895 Figure 6 10. Disconnect the black engine ground wire. g344817 Figure 7 11. Disconnect the fuel supply line at the fuel filter.
Engine Removal (continued) g349637 Figure 8 12. Disconnect the throttle cable. Throttle Cable Assembly Removal (page 5–26) 13. Disconnect the choke cable. Choke Control Assembly Removal (page 5–29) 14. Disconnect the clutch wire from the clutch. 15. Remove the (7/16 x 3 inch) clutch mounting screw and 2 washers. Slip the clutch off of the crankshaft. Note: Before removing the clutch, note the orientation of the clutch wire and the clutch. 16. Remove the engine pulley.
Engine Installation (continued) 9. Install the hydrostatic drive belt onto the machine. Hydrostatic Drive Belt Installation (page 7–8) 10. Install the deck drive belt onto the mower deck. Deck Drive Belt Installation (page 6–12) 11. Connect the clutch wire to the clutch. 12. Connect the choke cable. Choke Control Assembly Removal (page 5–29) 13. Connect the throttle cable. Throttle Cable Assembly Installation (page 5–27) 14. Connect the black engine ground wire. g344817 Figure 9 15.
Engine Installation (continued) g335893 Figure 11 17. Connect the fuel supply line to the fuel filter. g349637 Figure 12 18. Install the engine guard. 19. Open the fuel supply valve.
Engine Installation (continued) g344221 Figure 13 20. Fill the crankcase with approved oil and verify proper oil level. 21. Connect the battery by installing the positive cable first, then the negative cable to the battery. 22. Verify the proper function of the unit. 23. Verify the engine RPM is set to 3600 ± 100.
Engine: Service and Repairs Page 4–10 TITAN® Max Service Manual 3442-428 Rev A
Chapter 5 Chassis Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Caster Assembly and Bearing Replacement...................................................................................... 5–8 Caster Wheel Service .......................
General Information The Titan Max series uses a 11 GA fully welded frame with a Roll Over Protection System (ROPS).
Service and Repairs Chassis Assembly 1 g341890 Figure 14 1. Control Panel Assembly 2. 3. 4. 5. 6. RH Pod Cover Choke Control Cable RH Console Throttle Control Cable Upper Rear Trim 10. 11. 12. 13. 14. Muffler Guard Bracket RH Motion Control Cover LH Console Bracket LH Console LH Cover 7. RH Console Support 15. LH Motion Control Cover 8. Rear Guard Assembly TITAN® Max Service Manual 3442-428 Rev A 9.
Chassis Assembly 2 g341888 Figure 15 1. ROPS Assembly 5. Frame 2. Floor Mat 6. Step Plate 3. 4. Rubber Grommet Floor Pan Assembly 7. 8.
Chassis Assembly 3 g341892 Figure 16 1. Seat TITAN® Max Service Manual 3442-428 Rev A 2.
Chassis Assembly 4 g341891 Figure 17 1. Fuel Hose Assembly 2. Fuel Tank Chassis: Service and Repairs 3.
Chassis Assembly 5 g341894 Figure 18 1. Grease Cap TITAN® Max Service Manual 3442-428 Rev A 2.
Caster Assembly and Bearing Replacement Caster Assembly and Bearing Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 4. Using a hammer and flat head screw driver, remove the grease cap.
Caster Assembly and Bearing Removal (continued) g342956 Figure 21 8. Inspect the 2 bearings for wear or damage. Replace if necessary. 9. Inspect the inside of the axle bearing area for damage or excessive wear. Caster Assembly and Bearing Installation 1. Clean the surface inside the axle bearing area, keeping surface clean of debris. 2. Using a (32 mm) socket and a hammer, install the lower bearing from the bottom side into the axle. Verify the bearing is fully seated.
Caster Assembly and Bearing Installation (continued) g342957 Figure 22 4. Apply anti-seize to fork shaft before installing. 5. Install the caster from the bottom side of the frame and place flat washer on top of the bearing. 6. Install the (0.313-18NC x 0.750 inch) screw and tighten to the caster shaft. Torque the screw to 22.597 ± 2.82 N • m (200 ± 25 in-lb). g342955 Figure 23 7. Using a (32 mm) socket and a hammer, install the grease cap onto the frame. Note: Replace the grease cap if damaged. 8.
Caster Wheel Service Caster Wheel Disassembly 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 4. Remove the (0.50-13 inch) nut and (1/2–13 x 8.38 inch) screw securing the caster wheel to the caster fork.
Caster Wheel Disassembly (continued) g342890 Figure 26 8. Inspect the bearings for wear or damage and replace if necessary. Caster Wheel Assembly 1. Ensure that the wheel is clean and free of debris or excessive wear. 2. Using a (1 1/6 inch) socket and hammer, install the 2 bearings into the caster wheel. g342921 Figure 27 3. Install the caster wheel spanner into the caster wheel. 4. Install the 2 seal guards and washers onto the caster wheel hubs.
Caster Wheel Assembly (continued) g342889 Figure 28 5. Assemble the caster wheel onto the caster fork. 6. Install the (1/2–13 x 8.38 inch) screw and (0.50-13 inch) nut securing the wheel to the caster fork. Torque the screw to 8.47 ± 0.90 N • m (75 ± 8 in-lb). g342888 Figure 29 1. Nut 2. Screw 7. Lower the unit and verify proper function. 8. Connect the battery by installing the positive cable first, then the negative cable to the battery. Left Console Replacement Left Console Removal 1.
Left Console Removal (continued) 4. Remove the (T30) torx screw securing the left console to the chassis. g342987 Figure 30 1. Torx Screw 5. Remove the 2 screws (T30) securing the left console bracket to the chassis. g342988 Figure 31 6. Remove the fuel cap and disconnect the keeper line. Note: Ensure the keeper line does not fall into the fuel tank.
Left Console Removal (continued) g342993 Figure 32 7. Remove the left console from the machine. 8. Replace the fuel cap. Left Console Installation 1. Remove the fuel cap from the gas tank. 2. Lower the left console into place. Ensuring the left console seats properly on the support. g342994 Figure 33 3. Install the keeper line into the fuel cap. Install the fuel cap. 4. Install the 2 screws (T30) securing the LH console bracket to the chassis.
Left Console Installation (continued) g342988 Figure 34 5. Install the (T30) torx screw securing the LH console to the chassis. g342987 Figure 35 1. Torx Screw 6. Install the battery onto the battery tray and secure with the battery strap. 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. Right Console Replacement Right Console Removal 1. Park the machine on a level surface and disengage the PTO.
Right Console Removal (continued) g343007 Figure 36 4. Remove the 2 (T25) screws securing the console to the console bracket on the underside of the console. 5. Remove the (10–14 x 1/2 inch) plastic screw securing the control panel assembly to the console. 6. Lift the console upward off of the machine, while feeding the control panel assembly through the opening in the console. Note: The control panel assembly should be supported while servicing the machine, to avoid damage to cables or the wire harness.
Right Console Installation 1. Lower the console into place, while moving the control panel assembly through the opening in the console and into position. Verify the console seats properly on the supports. Note: Before securing the control panel to the console, ensure that all cables and electrical connections are seated firmly in place on the underside of the control panel assembly. g344218 Figure 38 2. Secure the control panel assembly to the console with a hex screw. 3.
Right Console Installation (continued) 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. Seat Replacement Seat Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Slide the seat forward. 4. Remove the 2 (5/16-18 inch) nuts and 2 (0.
Seat Removal (continued) g344219 Figure 41 6. Disconnect the seat switch from the seat. g344220 Figure 42 7. Remove the seat from the seat plate. Seat Installation 1. With the seat plate tipped forward, hold the seat on the seat plate. 2. Connect the seat switch to the seat.
Seat Installation (continued) g344220 Figure 43 3. Install the 2 wire retainers to the bottom of the seat and seat plate. g344219 Figure 44 4. Install the 2 (5/16-18 inch) nuts and 2 (0.312-18 x 1.000 inch) carriage screws securing the seat plate to the chassis. Torque the screws to 22.597 ± 2.82 N • m (200 ± 25 in-lb).
Seat Installation (continued) g344224 Figure 45 1. Nut 2. Carriage Screw 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. Fuel Tank Replacement Fuel Tank Removal Note: The fuel pick-up system is designed to pull fuel from any part of the tank in low fuel situations as well as reducing the affect of debris in the tank. g336089 Figure 46 1. Park the machine on a level surface and disengage the PTO.
Fuel Tank Removal (continued) g344221 Figure 47 4. Remove the left and rights consoles from the machine. Left Console Removal (page 5–13) Right Console Removal (page 5–16) 5. Remove the seat from the machine. Seat Removal (page 5–19) 6. Disconnect the fuel supply line and the 2 vent lines from the fuel tank. g336088 Figure 48 1. Vent Hose Assembly 2. Fuel Supply Line 3. Fuel Shut-Off Valve 7. Lift the fuel tank assembly from the machine by sliding the tank rearward and up, away from the frame.
Fuel Tank Installation (continued) g336088 Figure 49 1. Vent Hose Assembly 2. Fuel Supply Line 3. Fuel Shut-Off Valve 4. Install the seat onto the machine. Seat Installation (page 5–20) 5. Install the left and right consoles. Left Console Installation (page 5–15) Right Console Installation (page 5–18) 6. Open the fuel supply valve. g344221 Figure 50 7. Connect the battery by installing the positive cable first, then the negative cable to the battery.
Roll Over Protection System (ROPS) Removal (continued) Note: For easier access, remove the left and right side consoles. Left Console Removal (page 5–13) Right Console Removal (page 5–16) 4. Support the ROPS assembly and remove the 2 screws, 4 washers, and 2 nuts securing the LH ROPS assembly to the chassis. Repeat on the RH ROPS assembly. g344235 Figure 51 5. Lift and remove the ROPS assembly from the machine. Roll Over Protection System (ROPS) Installation 1.
Roll Over Protection System (ROPS) Installation (continued) 3. Torque the ROPS connecting hardware to 122–135.58 N • m (90–100 ft-lb). 4. If the left and right consoles were removed, install the left and right consoles. Left Console Installation (page 5–15) Right Console Installation (page 5–18) 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. Throttle Cable Assembly Replacement Throttle Cable Assembly Removal 1.
Throttle Cable Assembly Removal (continued) g344236 Figure 54 8. Remove the throttle cable from the throttle plate, noting the position of the cable in the plate. 9. Pull the throttle cable assembly through the console and out of the machine. Throttle Cable Assembly Installation 1. Route the throttle cable through the right console between the ROPS and the hydraulic fluid reservoir, under the fuel and vent lines, and under the electrical. g336057 Figure 55 2.
Throttle Cable Assembly Installation (continued) g336055 Figure 56 4. Install the throttle cable from the throttle plate. 5. Move the throttle control lever to the slow idle position. 6. Place the z-bend of the throttle cable in the throttle plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8. Tighten the clamp securing the throttle cable to the throttle plate. g344236 Figure 57 9.
Throttle Cable Assembly Installation (continued) 13. Connect the battery by installing the positive cable first, then the negative cable to the battery. 14. Verify the proper function of the unit. Choke Control Assembly Replacement Choke Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2.
Choke Control Assembly Installation (continued) 6. Place the z-bend of the choke cable in the choke plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8. Ensure that the choke control lever is pressed down fully and tighten the cable clamp. g344320 Figure 59 9. Install the rear guard to the main frame. 10. Install the 4 (5/16-18 x 2 3/4 inch) torx screws, 4 (5/16-18 inch) nuts, 2 (0.312-18 x 1.
Park Brake Handle Assembly Installation 1. Connect the upper brake linkage to the brake shaft. 2. With the park brake handle hardware orientated as shown, install the (0.375-16 x 1.500 inch) screw and (3/8-16 inch) flange nut. 3. With the park brake shaft in disengaged position and the park brake lever in the lower position, rotate the upper brake linkage until the end aligns with the hole in the park brake lever. 4. Secure with a locking cotter pin. 5.
Motion Control Assembly Removal (continued) g336044 Figure 61 9. Lower the motion control assembly through the frame toward the center of the machine, remove the assembly. Motion Control Assembly Installation 1. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 2. Position the motion control assembly in place with the linkage extending toward the transmission. 3. Secure the motion control assembly to the frame. g336044 Figure 62 4.
Motion Control Assembly Installation (continued) g336043 Figure 63 5. Adjust the nut on the motion control assembly until the motion control nut is centered in the control plate slot. 6. Install the motion control damper to the motion control assembly, secure with a (5/16-18 inch) shoulder screw. Torque the screw to 9.039–11.298 N • m (80-100 in-lb). 7. Install the motion control handle to the motion control assembly, secure with 2 (3/8-16 X 1.00 inch) screws. Torque the screw to 40.67 ± 4.
Chassis: Service and Repairs Page 5–34 TITAN® Max Service Manual 3442-428 Rev A
Chapter 6 Mower Deck Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Mower Deck Replacement ................................................................................................................. 6–5 Deck Drive Belt Replacement ..
General Information The Titan Max uses a 60 inch fabricated deck and a 4-point lift system. This includes a front deck strut for lateral stability. All units have a 0.59–1.77 cm (1.5-4.5 inch) height of cut range and are built from 10 GA steel.
Service and Repairs Mower Deck Assembly 1 g344576 Figure 64 1. 2. Deck Drive Belt Idler Pulley 11. 12. Deflector Plate Chute Pin 3. Flat Idler Pulley 13. Spindle Assembly 4. 5. RH Belt Cover Bearing Shield 14. 15. Cutoff Baffle Anti Scalp Roller 6. LH Belt Cover 16. Deck Step 7. Drive Blade Sheave 17. Deck Assembly 8. Idler Arm 18. Spindle Shaft 9. Discharge Deflector 19. Hi Flo Blade 10.
Mower Deck Assembly 2 g341897 Figure 65 1. 2. Lift Link Transport Lock Rod 3. Transport Lock Plate 4. Grommet 7. 8. Rear Deck Lift Shaft Deck Lift Gusset 9. Flange Bushing 10. Deck Strut Assembly 5. Lower Hoc Angle 11. Deck Chain Assembly 6. Bracket Assembly 12.
Mower Deck Replacement Mower Deck Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Place 2 (2x4) blocks underneath each side of the mower deck. g344396 Figure 66 4. Place the height of cut pin into the third hole to lock the mower deck in the lowest height-of-cut position.
Mower Deck Removal (continued) g344398 Figure 68 6. Using a spring removal tool, remove the spring from the mower deck. g344399 Figure 69 7. Remove the deck drive belt from the PTO clutch.
Mower Deck Removal (continued) g344400 Figure 70 8. Remove the 2 (0.375-16 x 2.250 inch) carriage screws, 2 (3/8-16) nuts, and 2 washers securing the deck strut assembly to the frame. g344401 Figure 71 9. Remove the 2 (3/8 inch) LH upper shoulder screws and 2 (3/8-16 inch) washers securing the deck support chains to the deck lift shaft. Repeat on the RH side of the machine.
Mower Deck Removal (continued) g344402 Figure 72 10. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 11. Remove the mower deck. Mower Deck Installation 1. Raise and support the unit so that the front wheels are off the ground, block the rear wheels. 2. Place the mower deck under the machine. 3. Lower the unit to the floor. 4. Install the 2 (3/8 inch) LH upper shoulder screws and 2 (3/8-16 inch) washers securing the deck support chains to the deck lift shaft.
Mower Deck Installation (continued) 5. Install the 2 (0.375-16 x 2.250 inch) carriage screws, 2 (3/8-16) nuts, and 2 washers securing the deck strut assembly to the frame. g344401 Figure 74 6. Install the deck drive belt to the PTO clutch. g344400 Figure 75 7. Using a spring removal tool, install the spring onto the mower deck.
Mower Deck Installation (continued) g344399 Figure 76 8. Install the floor pan onto the machine. g344398 Figure 77 9. Connect the battery by installing the positive cable first, then the negative cable to the battery. 10. Verify proper function of the unit. Deck Drive Belt Replacement Deck Drive Belt Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2.
Deck Drive Belt Removal (continued) g344397 Figure 78 4. Lift and remove the floor pan from the machine. g344398 Figure 79 5. Using a spring removal tool, remove the spring from the mower deck.
Deck Drive Belt Removal (continued) g344399 Figure 80 6. Remove the deck drive belt from the PTO clutch. g344400 Figure 81 7. Remove the 4 (0.250-20 x 0.500 inch) screws securing the LH belt cover to the mower deck. Remove the LH belt cover from the mower deck. Repeat on the RH side of the machine. 8. Loosen the (3/8-16 inch) nut securing the idler pulley to the idler arm. 9. Remove the deck drive belt from the mower deck. Deck Drive Belt Installation 1.
Deck Drive Belt Installation (continued) g344400 Figure 82 5. Using a spring removal tool, install the spring onto the mower deck. g344399 Figure 83 6. Install the floor pan onto the machine.
Deck Drive Belt Installation (continued) g344398 Figure 84 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. 8. Verify proper function of the unit. Mower Spindle Replacement Mower Spindle Removal 1. Remove the mower deck. Mower Deck Removal (page 6–5) 2. Remove the 4 (0.250-20 x 0.500 inch) screws securing the LH belt cover to the mower deck. Remove the LH belt cover from the mower deck. Repeat on the RH side of the machine. 3.
Mower Spindle Removal (continued) 7. From the topside of the mower deck, remove the (0.750-16 inch) spindle lock nut and washer securing the each spindle shaft to the drive blade sheaves. g344425 Figure 86 8. Remove each drive blade sheave and spindle shaft from the mower deck. 9. Remove the bearing shields. 10. Remove and discard the 6 (5.16-18 x 7/8 inch) taptite screws securing spindle assemblies to the mower deck. g344426 Figure 87 11. Remove the spindle assemblies from the mower deck. 12.
Mower Spindle Installation (continued) g344427 Figure 88 2. Install the spacers into the bottom of the spindles. 3. Using a (32 mm) socket and a hammer, install the bottom bearings into the spindles. 4. Install the spindle assemblies into the mower deck. 5. Install the 6 (5.16-18 x 7/8 inch) new taptite screws securing spindle assemblies to the mower deck. Torque the screws to 13.6–18.98 N • m (10–14 ft-lb). g344426 Figure 89 6. Install the bearing shields. 7.
Mower Spindle Installation (continued) g344425 Figure 90 9. Raise and support the mower deck. 10. From the underside of the mower deck, install the blade screw and washer securing each mower blade to the mower deck. Torque the screw to 135.58–149 N • m (100–110 ft-lb). g344424 Figure 91 11. Lower the mower deck to the ground to access the topside of the mower deck. 12. Install the deck drive belt onto the mower deck. 13. Install the LH drive belt cover to the mower deck, secure with 4 (0.250-20 x 0.
Belt Tensioner Removal (continued) 3. Remove the deck drive belt from the mower deck. 4. Remove the (3/8-16 inch) nut securing the idler pulley to the idler arm. g344577 Figure 92 5. Remove the idler belt guide, washer, idler pulley, idler bushing, and screw (0.375-16 x 2.5 inch) from the idler arm. Note: Take note of the position of the belt guide next to the idler arm. g344579 Figure 93 1. Flange Nut 5. Idler Bushing 2. 3. 4. Belt Guide Washer Flat Idler Pulley 6. 7. Idler Arm Screw 6.
Belt Tensioner Removal (continued) g344578 Figure 94 7. Remove the 2 washers, 6 friction washers, and spacer from the mower deck. g344580 Figure 95 1. Screw 4. Lift Lever Bushing 2. 3. Washer Friction Washer 5. 6. Idler Arm Washer 8. Remove the idler arm from the mower deck. 9. Inspect the 6 friction washers for damage. Replace if necessary. Belt Tensioner Installation 1. Install the (0.375-16 x 2.5 inch) screw into the underside of the idler arm.
Belt Tensioner Installation (continued) g344579 Figure 96 1. Flange Nut 5. Idler Bushing 2. 3. 4. Belt Guide Washer Flat Idler Pulley 6. 7. Idler Arm Screw 3. Place the washer and 3 friction washers over the hole where the end of the idler arm will be installed 4. Install the idler arm onto washer stack. 5. Install the spacer, 3 friction washers, and washer onto the end of the idler arm. g344580 Figure 97 1. Screw 4. Lift Lever Bushing 2. 3. Washer Friction Washer 5. 6.
Belt Tensioner Installation (continued) 6. Install the (3/8-16 x 1.750 inch) screw and (5/16-18 inch) nut securing the end of the idler arm to the mower deck. Torque the screw to 40.67 ± 4.067 N • m (30 ± 3 ft-lb). g344578 Figure 98 7. Verify the idler arm is installed in the correct orientation. 8. Install the deck drive belt onto the mower deck. 9. Install the LH belt cover onto the mower deck, secure with 4 (0.250-20 x 0.500 inch) screws. Repeat on the RH side of the 10.
Mower Deck: Service and Repairs Page 6–22 TITAN® Max Service Manual 3442-428 Rev A
Chapter 7 Hydrostatic Drive System Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Hydrostatic Drive Transmission Replacement....................................................................................
General Information The Titan Max series of mowers use Hydro-Gear hydrostatic transaxle ZT-3100. The drive uses an engine oil with a minimum rating of 9.0 cst (55 SUS) at 110 ºC (230 ºF) and an API classification of SL is recommended. A 20W50 engine oil has been selected for use by the factory and is recommended for normal operating procedures. The ZT-3100 oil capacity is 4.45 L (150 fl-oz) (with filters removed).
Service and Repairs Hydrostatic Drive Assembly 1 g341889 Figure 99 1. Hydraulic Tank 5. RH Transaxle Assembly 2. Hydraulic Hose 6. LH Transaxle Assembly 3. Hydraulic Routed Hose 7. Spacer Shaft 4.
Hydrostatic Drive Assembly 2 g341893 Figure 100 1. RH Control Handle Assembly 7. Brake Lever 2. RH Motion Control Assembly 8. LH Control Handle Assembly 3. Brake Bracket 9. LH Motion Control Assembly 4. Brake Shaft 10. Lower Brake Linkage 5. Adjustable Yoke 11. Damper 6.
Hydrostatic Drive Transmission Replacement Hydrostatic Drive Transmission Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 4. Remove the drive wheels. 5.
Hydrostatic Drive Transmission Removal (continued) 11. Remove the (0.375-16 x 2.00 inch) screw that connects the transmission to the cross shaft. 12. Remove the 2 (0.312-18 x 2.250 inch) front hydro mounting screws and 2 (5/16-18 inch) nuts. 13. Remove the 2 (5/16-18 x 4.75 inch) rear hydro mounting screws and 2 (5/16-18 inch) nuts. g336195 Figure 103 1. Front and Rear Mounting Screws 2. Cross Shaft 3. Axle Horn Screws 14.
Hydrostatic Drive Transmission Installation (continued) 3. Install the 2 (0.312-18 x 2.250 inch) front and 2 (5/16-18 x 4.75 inch) rear hydro mounting screws, washers, and (5/16-18 inch) nuts. Do not tighten at this time. 4. Torque the cross shaft screw to 61 ± 6.779 N • m (43 ± 5 ft-lb). 5. Tighten the rear hydro mounting screw. 6. Tighten the 2 axle horn screw. 7. Tighten the front hydro mounting screw. 8. Remove the protective cap from the hydraulic oil nipple (if installing a new hydrostatic drive).
Hydrostatic Drive Transmission Installation (continued) 18. Purge the air out of the system. Refer to the product Operator’s Manual the purging air procedures. 19. Adjust the neutral setting if necessary. Refer to the product Operator’s Manual for adjusting the neutral setting procedures. 20. Lower the unit and verify proper function. 21. Adjust the tracking if necessary. Refer to the product Operator’s Manual for the track adjusting procedures.
Chapter 8 Electrical System Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Fuse Block and Fuses .......................................................................................................................
General Information The Titan Max utilizes a 12VDC electrical system. The systems consist of a 300cca 12v battery. The system use 2 neutral lock switches on the motion control levers, seat switch, brake switch, blade engagement switch (PTO), ignition switch, 15 AMP main fuse, and 20 AMP charging system fuse. This system also uses a start relay, electric PTO clutch, hour meter, TVS diode, and starter solenoid.
Service and Repairs Electrical Assembly g341896 Figure 106 1. Module Assembly 2. 3. Hour Meter Ignition Key 8. Solenoid 9. 10. Switch Battery 4. Wire Harness Adapter 11. Wire Harness 5. Bungle Strap 12. Battery Tray 6. 7. PTO Switch Ignition Switch 13.
Fuse Block and Fuses The fuse block houses the fuses that protect the electrical system from electrical surges. Note: Always use Toro fuses when replacing a damaged or blown fuse. Fuse Block and Fuses Test 1. Visually inspect the fuses. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade. g336414 Figure 107 2. Using a digital multi-meter set to the OHM or Continuity setting, check the continuity between the fuse blades.
g350861 Figure 108 Key/Ignition Switch Test 1. Remove the control panel from the right console. 2. Disconnect the ignition switch from the wire harness. 3. Using a digital multi-meter set to the OHM or Continuity setting, verify that continuity exists between the terminals listed for each switch position. 4. Using a digital multi-meter set to the OHM or Continuity setting, verify that NO continuity exists between the terminals not listed for each switch position.
Hour Meter Status Check (continued) g336418 Figure 109 Operator Presence Switch (Seat Switch) With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the neutral switches. Note: The operator presence switch is part of the seat assembly. g336419 Figure 110 Operator Presence Switch (Seat Switch) Test 1. Disconnect the wire harness from the operator presence switch, located on the bottom of the seat assembly. 2.
Neutral Switch - Left and Right The neutral switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed, the circuit closes and there is continuity between the terminals. Motion control levers in neutral position (OUT), the switch will have continuity (closed). Motion control levers in the operating position (IN), the switch will NOT have continuity (open).
Starter Solenoid The solenoid is a remote switch that connects the battery to the starter motor when the ignition switch is turned to START. The solenoid protects the ignition switch from the high current drawn by the starter motor. g344833 Figure 113 Starter Solenoid Test 1. Disconnect the solenoid from the wiring harness. 2. With a multi-meter set to the OHM or continuity setting, check to ensure that terminals 1 and 2 are open (no continuity). 3.
g336408 Figure 115 Note: The engine will not crank over when the PTO switch is in the ON position. All switches are supplied in parallel and feed into the Hour Meter. PTO Switch Test 1. Remove the control panel from the right console. 2. Disconnect the PTO switch from the wire harness. 3. With the switch in the ON position (button pulled OUT). g336409 Figure 116 4.
PTO Switch Test (continued) • Pin 2 and 5 should NOT have continuity (open) Electric PTO Clutch The PTO clutch electronically controls the engagement and disengagement of the PTO pulley (deck belt). The PTO clutch is composed of three major components: • Field • Clutch Plate • Friction Plate The clutch plate always turns with the engine (crankshaft). The field is a coil of wire on an iron core which becomes an electromagnet when power is applied.
Electric PTO Clutch Removal (continued) g344398 Figure 118 5. Using a spring removal tool, remove the spring from the mower deck. g344399 Figure 119 6. Remove the deck drive belt from the PTO clutch.
Electric PTO Clutch Removal (continued) g344400 Figure 120 7. Disconnect the clutch wire connector from the PTO clutch. g336161 Figure 121 8. Remove the screw and 2 spring washers securing the PTO clutch to the machine. 9. Remove the PTO clutch from the machine. Electric PTO Clutch Installation 1. Install the PTO clutch onto the underside of the machine, secure with the 2 spring washers and (7/16 x 3 inch) screw. Torque the screw to 66.4–82.7 N • m (49–61 ft-lbs). 2.
Electric PTO Clutch Installation (continued) g336161 Figure 122 3. Install the deck drive belt onto the PTO clutch. g344400 Figure 123 4. Using the spring removal tool, install the spring onto the mower deck.
Electric PTO Clutch Installation (continued) g344399 Figure 124 5. Install the floor pan onto the machine. g344398 Figure 125 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. 7. Verify the proper function of the machine. Electric PTO Clutch-Coil Resistance Measurement Test If the PTO clutch is not engaging or is suspect as a cause of electrical problems, use the following electrical troubleshooting steps.
Electric PTO Clutch-Coil Resistance Measurement Test (continued) g336410 Figure 126 5. See the PTO Clutch Electrical Specifications chart. Resistance (OHMs) 3.05 ± 5% AMP Draw Continuity to Ground 3.93 OPEN Electric PTO Clutch- PTO Clutch Continuity to Ground Test 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the clutch wire connector. 3.
Electric PTO Clutch- Measuring Clutch Current Draw (continued) g336411 Figure 127 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the clutch wire connector. 3. Set the multi-meter to measure amps (10 amp scale). 4. Connect the positive meter lead to the chassis harness terminal 1. 5. Connect the negative meter lead to the corresponding wire terminal 2. 6.
g336413 Figure 128 TVS Diode Testing If the main fuse blows each time the PTO clutch is engaged, check the TVS diode. 1. Disconnect the TVS diode from the harness. 2. Connect each lead of the meter to each terminal of the TVS diode. 3. If the TVS diode is internally shorted, replace the TVS diode. 4. If the TVS diode is not internally shorted, check the wiring and the clutch.
Electrical System: Service and Repairs Page 8–18 TITAN® Max Service Manual 3442-428 Rev A
Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations........................................................................................................A–2 Kohler Engine Electrical Schematic ...................................................................................................
Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color BK Black BR or BN Brown BU Blue GN Green GY Gray OR or OG Orange PK Pink R or RD Red T or TN Tan VIO or VT Violet W or WH White Y or YE Yellow Numerous harness wires include a line with an alternate color. These wires are identified with the wire color followed by a / or _ and then the line color (e.
Kohler Engine Electrical Schematic g350654 , Drawing Rev A, Sheet 1 3442-428 Rev A Page A–3
